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REFERENCE NO: E22 - MASHOP 1 1. COURSE NAME: Machine Shop 1 2.

COURSE DESCRIPTIONS: The course includes the Safe Working Practices, Hand Tools and Measuring Equipment for Dismantling, Maintenance, Repair and Re-Assembly of Shipboard Plant and Equipment and Fabrication and Repair. 3. NUMBER OF UNITS FOR LECTURE AND LABORATORY: 1 LECTURE, 2 LABORATORY = 3 UNITS 4. NUMBER OF CONTACT HOURS PER WEEK: 1 LECTURE, 6 LABORATORY = 7 HOURS 5. PREREQUISITE: Engineering materials 6. COURSE OBJECTIVES: The students shall be able: 6.1 to properly use hand, power and measuring tools to carry out normal maintenance, repairs and fabrication works onboard ships with safety as the primary concern. 6.2 to perform Benchwork and Tinsmithing and joining of metals FUNCTION: F1 - Marine Engineering at the Operational Level (Use of appropriate tools, Handtools and Measuring Equipment) 7. COURSE OUTLINE: LEARNING OBJECTIVES/OUTCOMES: The students shall be able to . . . . . . 7.1 Safe Working Practices 7.1.1. Safety 7.1.1.1 list typical identifiable and non-identifiable hazards in an engineering environment 7.1.1.2 describe the procedure to ensure safety when using a grinding machine 7.1.1.3 demonstrate an awareness of the dangers which exist when using a lathe 7.1.1.4 use the correct practice to avoid accidents when using a drilling machine 7.1.1.5 describe the control necessary over the power supply to a machine tool 7.1.1.6 list the processes for which the power supply to a machine must be isolated
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7.1.1.7

describe the basic differences between stop and start buttons 7.1.1.8 describe the purpose and sitting of emergency stop buttons 7.1.1.9 describe the situations where the following should be worn 7.1.1.9.1 safety helmets 7.1.1.9.2 eye protection 7.1.1.9.3 protective footwear 7.1.1.9.4 skin protection 7.1.1.10 tate when hands and arms should be washed with soap and water 7.1.1.11 describe the care necessary for hands, including that for any cuts or abrasions 7.2 Use Hand Tools and Measuring Equipment for Dismantling, Maintenance, Repair and Re-Assembly of Shipboard Machinery and Equipment 7.2.1 Use of Hands and Power Tools 7.2.1.1 Marking Out 7.2.1.1.1 demonstrate the care of : 7.2.1.1.1.1 surface plate 7.2.1.1.1.2 vee blocks 7.2.1.1.2 demonstrate the care of : 7.2.1.1.2.1 scribers 7.2.1.1.2.2 dividers 7.2.1.1.2.3 odd-leg calipers 7.2.1.1.3 explain the uses of 60 degrees and 90 degrees punches 7.2.1.1.4 state when a scriber should not be used for marking out 7.2.1.1.5 use the tools included in the above objectives to mark out simple exercises, working from: 7.2.1.1.5.1 datum faces 7.2.1.1.5.2 datum lines 7.2.1.2 Hand Tools 7.2.1.2.1 explain the use of a hacksaw 7.2.1.2.2 identify the types of hacksaw blade available and describes their application 7.2.1.2.3 explain the general relationships between tooth pitch of a hacksaw blade and the hardness and thickness of the material to be cut 7.2.1.2.4 select the correct hacksaw blade for a given job and fits it into a saw frame with the correct tension 7.2.1.2.5 demonstrate, using a hacksaw, the correct technique, to cut common materials, including thin-walled pipe 7.2.1.2.6 explain the use of files 7.2.1.2.7 name the correct file selection to be used for given situations
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identify the following files, explaining their use: 7.2.1.2.8.1 double-cut rough, second-cut and smooth 7.2.1.2.8.2 single-cut smooth and second cut 7.2.1.2.9 demonstrate the care of, and safety precautions necessary when using files 7.2.1.2.10 use rough and finishing files correctly on given exercises 7.2.1.2.11 describe the uses of flat and half-round scrapers 7.2.1.2.12 demonstrate how scrapers are sharpened and cared for 7.2.1.2.13 use scrapers correctly on given exercises 7.2.1.2.14 explain the use of chisels 7.2.1.2.15 describe the use of the following cold chisels: 7.2.1.2.15.1 flat 7.2.1.2.15.2 cross-cut 7.2.1.2.15.3 diamonds-cut 7.2.1.2.15.4 round-nose 7.2.1.2.16 describe the safety measures necessary when using a chisel 7.2.1.2.17 use and sharpens a chisels listed in the above objective in a correct and safe manner 7.2.1.3. Thread Cutting 7.2.1.3.1 explain the purpose of tapers second plug taps 7.2.1.3.2 explain what governs the diameter of the hole to be drilled prior to tapping 7.2.1.3.3 explain the difference in use of a die nut and stock and die 7.2.1.3.4 describe the different techniques used in cutting: small-diameter threads large-diameter and fine threads 7.2.1.3.5 cuts internal threads in open-ended and blind holes and external threads on small- and large-diameter rod 7.2.1.4. Powered Hand Tools 7.2.1.4.1 name the types of power used in hand tools 7.2.1.4.2 identifies the processes for which powered hand tools might be used 7.2.1.4.3 state the practical maximum and minimum capacities of an electrically powered hand drill 7.2.1.4.4 explain the care necessary for the supply cables of powered hand tools 7.2.1.4.5 use powered hand tools safely and correctly and care required 7.2.1.5. Measurement 7.2.1.5.1 explain why dimensional control is necessary

7.2.1.2.8

7.2.1.3.4.1 7.2.1.3.4.2

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7.2.1.5.2 state the difference between functional and nonfunctional dimensions and the relative tolerance given to each 7.2.1.5.3 demonstrate the use of a common datum when using a steel tube 7.2.1.5.4 state the accuracy obtainable using a steel rule 7.2.1.5.5 use inside and outside callipers to measure diameters 7.2.1.5.6 use a try-square to check 90 degrees angles 7.2.1.5.7 checks a try-square for accuracy against a master square 7.2.1.5.8 use a bevel gauge and a plain protractor to check and mark out angles 7.2.1.5.9 use small-scale vernier callipers to measure internal and external dimensions to an accuracy of 0.02 mm 7.2.1.5.10explain the principles of the vernier caliper 7.2.1.5.11 explain the purpose of the ratchet fitted to a mechanical micrometer 7.2.1.5.12state the accuracy of micrometer measurements 7.2.1.5.13check and adjusts the zero reading of a micrometer 7.2.1.5.14list measuring instruments which use the micrometer principle 7.2.1.5.15 demonstrate the care of micrometer instruments 7.2.1.5.16use micrometers correctly and accurately 7.2.1.5.17state that the vernier principle can be applied to micrometers to give greater accuracy 7.2.1.5.18explain briefly why and how dimensions of components are checked by comparison 7.2.1.5.19explain the principle of operation of a standard dial test indicator plunger-type comparator 7.2.1.5.20use a standard dial test indicator to compare dimensions 7.2.1.6 Drilling Machines 7.2.1.6.1 list the uses of a drilling machines 7.2.1.6.2 state engineering terms used to describe geometrical surfaces and vice-versa 7.2.1.6.3 explain briefly how drills are held in a machine 7.2.1.6.4 explain how a workpiece is held place, emphasizing dangerous practice and the particular problem when drilling thin plate 7.2.1.6.5 name the types of drilling machines used in engineering workshops 7.2.1.6.6 relate the approximate limits on drill diameters and the uses of the machines listed in the above objective 7.2.1.6.7 state that accurate drilling is very difficult to achieve 7.2.1.6.8 state the general relationship between drill diameter and rotational speed 7.2.1.6.9 explain how feed rates are determined
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7.2.1.6.10lists the operation which can be carried out by using a pillar drilling machine 7.2.1.6.11 explain how feed is provided to the drill on the pillar machine 7.2.1.6.12relate spindle speeds to those of a sensitive machine 7.2.1.6.13describe the care necessary to avoid accidents when using automatic feed 7.2.1.6.14describe the procedure for inserting and removing drills with parallel and with tapered shanks 7.2.1.6.15list the steps taken to: 7.2.1.6.15.1 set up work 7.2.1.6.15.2 drill 7.2.1.6.15.3 counterbore, ream or countersink 7.2.1.6.16explain its simple term the difference between the worktables used on pillars machines 7.2.1.6.17describe the care necessary when using automatic feed 7.2.1.7. Drills 7.2.1.7.1 sketch the cutting face of a twist drill, showing; 7.2.1.7.1.1 the land 7.2.1.7.1.2 rake angle 7.2.1.7.1.3 clearance angle 7.2.1.7.2 explain the care necessary when using twist drills 7.2.1.7.3 explain the principal uses of the following drills and tools: 7.2.1.7.3.1 parallel-shank jobber series 7.2.1.7.3.2 stub 7.2.1.7.3.3 parallel-shank long series 7.2.1.7.3.4 Morse-taper-shank series 7.2.1.7.3.5 two- three- and four-fluted drills 7.2.1.7.3.6 reamers - hand and machine 7.2.1.7.3.7 counter sinker 7.2.1.7.3.8 spotfacer 7.2.1.7.4 state the normal allowances on hole diameter for reaming 7.2.1.7.5 explain how speeds and feeds are affected with when: 7.2.1.7.5.1 reaming 7.2.1.7.5.2 countersinking 7.2.1.7.6 explain the care necessary when driling plastics 7.2.1.7.7 use drilling machines to carry out all of the processes included in the above objectives correctly 7.2.1.7.8 sharpen twist drills safely and correctly 7.2.1.8. Heat treatment of Carbon Steel 7.2.1.8.1 explain the purpose of heat treatment 7.2.1.8.2 list four basic heat treatments 7.2.1.8.3 explain the purpose of four basic heat treatments
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7.2.1.8.4

describe the following processes and the types of steel to which they might be applied: 7.2.1.8.4.1 annealing 7.2.1.8.4.2 normalizing 7.2.1.8.4.3 hardening 7.2.1.8.4.4 tempering 7.2.1.8.5 complete items of deleted information in a table which gives the following 7.2.1.8.5.1 temperatures (230 to 320 degrees C) 7.2.1.8.5.2 color 7.2.1.8.5.3 application conditions 7.2.1.8.5.4 typical tool applications 7.2.1.8.6 explain how component is tempered throughout its whole section 7.2.1.8.7 carry out the heat treatments listed in the above objective 7.2.1.8.8 test a hardened and tempered cutting edge taking the necessary safety precautions 7.2.1.9. Adhesives and Bonding Health and Safety 7.2.1.9.1 explain the care necessary when using adhesives, to include: 7.2.1.9.1.1 skin protection 7.2.1.9.1.2 storage 7.2.1.9.1.3 fire 7.2.1.9.1.4 toxicity 7.2.1.9.2 state the advantages and disadvantages of adhesive bonding 7.2.1.9.3 describe the basic principles of joining by using an adhesive 7.2.1.9.4 sketch the four joint configurations 7.2.1.9.5 describe the principle testing for shear strength and peel strength of adhesives 7.2.1.9.6 compare the strength of parent material to that of s wellmade joint 7.2.1.9.7 explain the principle of bonding friction linings to steelshoes or discs 7.2.1.9.8 explain the principle of bonding smooth surfaces and states applications 7.2.1.9.9 identify a cemented joint 7.2.1.9.10 state the source of early adhesives 7.2.1.9.11 state the purpose of an activator when using an epoxy resin 7.2.1.9.12 state the significance of pot file
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7.2.1.9.13 explain the limitation on the service conditions of epoxy resins 7.2.1.9.14 state the special epoxy resins are made to meet particular service conditions 7.2.1.9.15 list the steps necessary when bonding together: 7.2.1.9.15.1 two metal components 7.2.1.9.15.2 friction material steel 7.2.1.9.16 describe briefly metal-to-metal bonding and applications using: 7.2.1.9.16.1 liquid or paste 7.2.1.9.16.2 beads or dry film Joining Plastics 7.2.1.9.17 state the three methods of joining plastics 7.2.1.9.18 state the need to use the correct adhesive for the plastic to be joined 7.2.1.9.19 describe the principle of solvent welding 7.2.1.9.20 describe the principle of welding plastics 7.2.1.9.21 select and uses the correct adhesive for a variety of applications for a variety and strength tests included in the above objectives 7.3 Fabrication and Repair 7.3.1 Permanent Joints 7.3.1.1 list the different ways of making permanent joints 7.3.2 Rivetting 7.3.2.1 explain why not rivetting is sometimes used 7.3.2.2 describe the principles of common forms of rivetted joint 7.3.2.3 list the range of rivets commonly used including metal to metal 7.3.2.4 make a cold-rivetted joints 7.3.3 7.3.3.1 7.3.3.2 Soldering explain why brazing is used describe the basic principles of soldering

Soft Soldering 7.3.3.3 7.3.3.4 7.3.3.5 soldering iron 7.3.3.6 soldering 7.3.3.7
E22 - MASHOP 1

explain the limitations of soft-soldered joints and the reason explain how soft-soldered joints might be strengthened with the aid of a simple sketch, describe the uses of state the main hazards and precautions necessary when tin a soldering iron and makes a soft-soldered joints
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7.3.3.8 7.3.3.9 7.3.3.10 fluxes:

describe the process of sweating joints explain the need for a flux, its application and its removal know the differences between the uses of the following

7.3.3.10.1passive 7.3.3.10.2active 7.3.3.11 explain the differences between (including the approximate melting temperature) and the uses of: 7.3.3.11.1 plumbers solder 7.3.3.11.2 tinmans solder Hard Soldering 7.3.3.12 7.3.3.13 tate the reasons for hard soldering identify the metals which can be joined by: 7.3.3.13.1silver solder 7.3.3.13.2brazing 7.3.3.13.3bronze welding 7.3.3.14 tate the processes to be followed stating the approximate melting point, when: 7.3.3.14.1silver soldering 7.3.3.14.2brazing 7.3.3.14.3bronze welding 7.3.3.15 ake soft and hard-soldering joints 7.3.4 Self-secured joints 7.3.4.1 sketch the stages of making self-secured joints 7.3.4.2 make self-secured joints 7.3.5 Safety and Health when Welding 7.3.5.1 state the protective clothing to be worn when welding at the bench 7.3.5.2 state the additional protection necessary when welding in more difficult situations 7.3.5.3 state the measures necessary to protect other personnel when welding 7.3.5.4 state the precautions related specifically to gas welding 7.3.5.5 explain the effect of radiation from welding on the eyes and skin 7.3.5.6 describe the dangers of fume on welding and how this should be dealt with 7.3.5.7 explain the principles of precautions to be taken when welding or when a similar heating process is to be performed in tanks which have contained combustibles 7.3.5.8 state the precautions to be taken when working in confined spaces
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7.3.5.9 state the care and precautions necessary when handling and storing compressed gas cylinders with particular reference to acetylene and oxygen 7.3.6 Plate-Work Marking Out 7.3.6.1 use correctly: 7.3.6.1.1 a chalk line 7.3.6.1.2 a flat square 7.3.6.1.3 a trammel bar 7.3.6.1.4 surface colouring 7.3.6.1.5 large dividers 7.3.6.1.6 odd-leg calipers 7.3.7 Thermal Cutting 7.3.7.1 state that applications of flame and plasma-arc cutting 7.3.7.2 explain the principles upon which oxygen is used to cut iron 7.3.7.3 describe the conditions necessary in order to cut when using an oxygen-fuel gas mixtures 7.3.7.4 identify the common engineering metals which can and cannot be cut using an oxygen-fuels gas mixture 7.3.7.5 list the gases commonly used as fuels 7.3.7.6 identify the controls a gas cutting blowpipe and demonstrates their purpose 7.3.7.7 explain the factors which can affect the quality of cutting 7.3.7.8 state the basic principles of plasma-arc cutting 7.3.7.9 use oxygen-fuel gas cutting torch to cut straight lines and curves in mild steel plate up to 10mm thick to crop mild steel sections Mechanical Cutting 7.3.8.1 describe the principle upon which mechanical cutting is based 7.3.8.2 explain the basic differences between: 7.3.8.2.1 hand shears 7.3.8.2.2 guillotine or bench shears 7.3.8.2.3 a shear machine 7.3.8.2.4 a nibbler 7.3.8.3 state the maximum thickness of mild steel plate that can normally be cut by bench shears 7.3.8.4 cut sheet steel by mechanical means Forming

7.3.8

7.3.9

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7.3.9.1 7.3.9.1.1 7.3.9.1.2 7.3.9.1.3 7.3.9.1.4

describe the principles of basic methods of plate forming including: pyramid roll initial-pinch bending rolls press brake hand operated folding machine state the maximum thickness of mild steel which can be bent using a hand operated machine describe the effect of varying the width of the vee when bending plate relate the width of the vee to the inside radius of the bent plate illustrate by means of sketch what is meant by development of a sheet metal component estimate lengths of plate, to include bending allowances list equipment required to bend thin steel plate without a bending machine explain the dangers encountered in sheet-metal work and the precautions to be taken design and constructs simple container from thin plate

7.3.9.2 7.3.9.3 7.3.9.4 7.3.9.5 7.3.9.6 7.3.9.7 7.3.9.8 7.3.9.9

7.3.10 Bonding Plates 7.3.10.1 describe the principle of bending plastics 7.3.10.2 state the range of softening temperature of plastics 7.3.10.3 explain the care and safeguards necessary when heating plastics 7.3.11 Inspection 7.3.11.1 construct a checklist for visual inspection during: 7.3.11.1.1 electric welding 7.3.11.1.2 gas welding 7.3.11.2 construct a list of the points to check visually after welding is completed 7.3.11.3 explain the limitations of visual inspection 7.3.11.4 carry out the following destructive tests on welded joints: 7.3.11.4.1 bend 7.3.11.4.2 macroscopic 7.3.11.4.3 nick-break 7.3.11.5 carry out penetrant tests on welded joints 7.3.11.6 describe the principle of: 7.3.11.6.1 ultrasonic inspection 7.3.11.6.2 microscopic inspection 7.3.11.7 list common weld defects and their caused 7.3.12 Pipework
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7.3.12.1 determine minimum bend radius with regard to pipe diameter, thickness, material and process to be used 7.3.12.2 select pipe filter 7.3.12.3 observe safety precautions 7.3.12.4 bend pipes, using both cold and hot techniques 7.3.12.5 remove bulk filter and residue 7.3.12.6 check for ovality, thinning and other defects 7.3.12.7 anneal, normalizes or stress-relieves as necessary 8. EQUIPMENT, MATERIALS, CHEMICALS, TEACHING AIDS: The equipment, materials, chemicals, teaching aids needed in this course is listed in the attached APPENDIX 1. 9. REFERENCES: 9.1 and ii. 9.2 9.3 9.4 9.5 9.6 Burghard, Axelred and Anderson. Machine tool operation part i Anderson. Shop theory. Lascoe, et,al.Machine Shop Operation and Set Up. Dalaguete, Felicito. Machine Shop 1. Dalaguete, Felicito. Machine Shop Practice. 1999. Nelson. Fundamentals of Tool Design. 1986.

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